Insert for heat exchanger

ABSTRACT

An insert is configured to be inserted into a heat exchanger having a plurality of tubes. The insert includes a base and a multiple blades. The blades are extended from the base. At least one of the blades has a spring portion. The spring portion is resiliently deformable and configured to be resiliently inserted between two of the tubes. The spring portion includes two arms. One of the two arms has one thin portion defining one recess dented in one direction in a thickness direction. The other of the two arms has the other thin portion defining the other recess dented in the other direction in the thickness direction. The one thin portion and the other thin portion are resiliently movable in a width direction within a clearance formed by the recesses, while overlapping one another in the thickness direction.

CROSS-REFERENCE TO RELATED APPLICATION

The application claims the benefit of U.S. application Ser. No.14/193,057, filed on Feb. 28, 2014, and the benefit of U.S. applicationSer. No. 14/492,157, filed on Sep. 22, 2014. The entire disclosures ofthe above applications are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to an insert for a heat exchanger.

BACKGROUND

A vehicle is generally equipped with an air conditioner having arefrigerant cycle. The refrigerant cycle generally includes anevaporator for cooling air drawn into a cabin of the vehicle. It may bedesirable to provide individually conditioned air to a front compartmentand a rear compartment in the vehicle at different conditions such asdifferent temperatures.

SUMMARY

According to an aspect of the disclosure, an insert for a heat exchangerhas a plurality of tubes. The insert includes a base and a plurality ofblades. The plurality of blades extend from the base. At least one ofthe blades has a spring portion, which is resiliently deformable andconfigured to be resiliently inserted between two of the tubes. Thespring portion includes two arms. One of the two arms has one thinportion defining one recess dented in one direction in a thicknessdirection. An other of the two arms has an other thin portion definingan other recess dented in an other direction in the thickness direction.The one thin portion and the other thin portion are resiliently movablein a width direction within a clearance formed by the recesses, whileoverlapping one another in the thickness direction.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the presentinvention will become more apparent from the following detaileddescription made with reference to the accompanying drawings. In thedrawings:

FIG. 1 is a perspective view showing an evaporator and inserts;

FIG. 2 is a schematic view showing the evaporator in an HVAC case;

FIG. 3 is a sectional view showing the evaporator and inserts to beinserted in the evaporator;

FIG. 4 is a sectional view showing the evaporator and inserts insertedin the evaporator;

FIG. 5 is a top view showing a blade of one insert;

FIG. 6 is a sectional view showing one insert to be inserted in theevaporator;

FIG. 7 is a sectional view showing one insert being inserted in theevaporator;

FIG. 8 is a sectional view showing one insert inserted in theevaporator;

FIG. 9A is a sectional view showing a spring portion of the bladeaccording to a first embodiment, FIG. 9B is a sectional view showing aspring portion of a blade according to a first modification of the firstembodiment, FIG. 9C is a sectional view showing a spring portion of ablade according to a second modification of the first embodiment, andFIG. 9D is a sectional view showing a spring portion of a bladeaccording to a third modification of the first embodiment;

FIG. 10 is a sectional view showing one insert inserted in theevaporator according to a second embodiment;

FIG. 11 is a top view showing inserts according to a third embodiment;

FIG. 12 is a rear view showing inserts according to the thirdembodiment;

FIG. 13 is a sectional view showing inserts according to the thirdembodiment;

FIG. 14 is a top view showing inserts according to a fourth embodiment;

FIG. 15A is a perspective sectional view showing a blade of one insertaccording to the fourth embodiment, and FIG. 15B is a perspectivesectional view showing the blade of FIG. 15A on application of anexternal force; and

FIG. 16 is a schematic view showing the evaporator in an HVAC caseaccording to a fifth embodiment.

DETAILED DESCRIPTION First Embodiment

As follows, a first embodiment of the present disclosure will bedescribed with reference to drawings. In the description, a verticaldirection is along an arrow represented by “VERTICAL” in drawing(s). Alateral direction is along an arrow represented by “LATERAL” indrawing(s). A depth direction is along an arrow represented by “DEPTH”in drawing(s). A thickness direction is along an arrow represented by“THICKNESS” in drawing(s). A length direction is along an arrowrepresented by “LENGTH” in drawing(s). A width direction is along anarrow represented by “WIDTH” in drawing(s).

As shown in FIG. 1, an evaporator 500 (heat exchanger) includes an uppertank 510, a lower tank 550, multiple tubes 600, and multiple fins 700.The upper tank 510, the lower tank 550, the tubes 600, and the fins 700are integrated with each other and brazed into one component. Theevaporator 500 functions as a component of a refrigerant cycle tocirculate a thermal medium, such as CO2, therethrough. The refrigerantcycle includes, for example, the evaporator 500, a thermal expansionvalve, a compressor, and a condenser (none shown), which are connectedwith each other via unillustrated pipes. The upper tank 510 includes aninlet 512 and an outlet 514. The inlet 512 is connected with the thermalexpansion valve via a pipe. The outlet 514 is connected with thecompressor via a pipe.

The tubes 600 and the fins 700 are stacked alternately in the lateraldirection to form a core. The alternately stacked tubes 600 and fins 700are interposed between the upper tank 510 and the lower tank 550 at bothends. One ends of the tubes 600 on the upper side are inserted into theupper tank 510 and communicated with a fluid space formed in the uppertank 510. The other ends of the tubes 600 are inserted into the lowertank 550 and communicated with a fluid space formed in the lower tank550. Thus, the upper tank 510, the tubes 600, and the lower tank 550form a fluid passage to flow the thermal medium therethrough.

Each of the fins 700 is extended in the vertical direction and isinterposed between adjacent tubes 600 in the lateral direction. The fin700 and the adjacent tubes 600 form air passages to flow airtherethrough. The fins 700 enhance a performance of heat exchangebetween the thermal medium, which flows through the tubes 600, with air,which passes through the air passages.

The core includes a first section 520, an intermediate section 530, anda second section 540. The intermediate section 530 is located betweenthe first section 520 and the second section 540. The intermediatesection 530 is located around the chain line III-Ill in FIG. 1. Each fin700 of the first section 520 extends downward from its upper end to theintermediate section 530. Each fin 700 of the second section 540 extendsfrom its lower end upward to the intermediate section 530. Thus, eachfin 700 of the first section 520 and the corresponding fin 700 of thesecond section 540 form a clearance 532 therebetween in the verticaldirection. The fins 700 of the first section 520 stacked in the lateraldirection and the fins 700 of the second section 540 stacked in thelateral direction form the clearances 532, which are linearly arrangedin the lateral direction.

The evaporator 500 is configured to be equipped with a fore insert(first insert) 10 and a rear insert (second insert) 60 to partition theevaporator 500 into the first section 520 and the second section 540. InFIG. 1, the inserts 10 and 60 are to be inserted into the clearances 532between the first section 520 and the second section 540 along the boldarrows. The fore insert 10 includes multiple blades (first blades) 20extended from a base 12. The blades 20 are configured to be insertedinto the clearances 532, respectively. The rear insert 60 also includesmultiple blades (second blades) 70 extended from a base 62. The blades70 are configured to be inserted into the clearances 532, respectively.The fore insert 10 may be identical to the rear insert 60.

FIG. 2 shows a heater and ventilator air conditioner (HVAC) system. InFIG. 2, the evaporator 500 is equipped in a case 400 of the HVAC system.The case 400 has partitions 430 to partition an interior of the case 400into an upper passage 420 and a lower passage 440. The inserts 10 and 60are inserted in the evaporator 500 and are connected with the partitions430, respectively.

The bold arrows show airflows in the upper passage 420 and the lowerpassage 440, respectively. The inserts 10 and 60 enables the upperpassage 420 on the upstream side of the first section 520 to communicatewith the upper passage 420 on the downstream side of the first section520 through the first section 520. The inserts 10 and 60 further enablesthe lower passage 440 on the upstream side of the second section 540 tocommunicate with the lower passage 440 on the downstream side of thesecond section 540 through second section 540.

A heater core and doors (none shown) are provided at the downstream ofthe first section 520 and the second section 540 of the evaporator 500to heat air after passing through the evaporator 500 and to conduct theair into the front compartment 810 and the rear compartment 820separately in the vehicle. In the present example, the upper passage 420and the lower passage 440 are provided with a front fan 710 and a rearfan 720, respectively, to cause airflows separately.

The front fan 710 and the rear fan 720 flow air through the upperpassage 420 and the lower passage 440, respectively, and through thefirst section 520 and the second section 540 of the evaporator 500,respectively. Thus, the air flowing through the first section 520 andthe air flowing through the second section 540 are conditioned, i.e.,cooled separately. Thus, the conditioned air is conducted toward thefront compartment 810 and the rear compartment 820 separately. In thepresent configuration, the inserts 10 and 60 function to restrict airfrom crosstalk (leakage) between the upper passage 420 and the lowerpassage 440. As shown by dotted arrow in FIG. 2, the airflows may causea small crosstalk by an allowable quantity.

FIG. 3 is a sectional view showing the intermediate section 530 of theevaporator 500 taken along the line III-Ill in FIG. 1. FIG. 3 shows theintermediate section 530 before being equipped with the inserts 10 and60 in the clearances 532. FIG. 4 is a sectional views showing theintermediate section 530 of the evaporator 500 being equipped with theinserts 10 and 60 in the clearances 532. In FIGS. 3, 4 and in FIGS. 6 to8 and 10 mentioned later, hatching for showing cross sections of thetubes 600 and reinforcement 680 are omitted.

As shown in FIG. 3, the fore insert 10 is to be inserted from one sidein the depth direction, and the rear insert 60 is to be inserted fromthe other side in the depth direction. The depth direction issubstantially in parallel with a direction of the airflow described withreference to FIG. 2. The evaporator 500 includes two rows of the tubes600 arranged, with respect to the airflow, on the upstream side and onthe downstream side, respectively. Each row includes tubes 600, whichare arranged in parallel along the lateral direction. The tubes 600interpose the fins 700 alternately therebetween. Each fin 700 extends inthe depth direction between the two rows to bridge the tubes 600 in thetwo rows. The evaporator 500 is equipped with reinforcements 680 atends, respectively.

As shown in FIG. 4, the fore insert 10 is inserted into the evaporator500 from the upstream side of airflow, and the rear insert 60 isinserted into the evaporator 500 from the downstream side of airflow. Inthe state of FIG. 4, each blade 20 is inserted into the correspondingclearance 532. Thus, each blade 20 is interposed between adjacent twotubes 600 or interposed between the tube 600 and the reinforcement 680,which are adjacent to each other. In the state of FIG. 4, thecomb-shaped fore insert 10 and the comb-shaped rear insert 60 areopposed to each other in the depth direction. The blades 20 of the foreinsert 10 and the blades 70 of the rear insert 60 are arrangedalternately and located substantially at the same level in the verticaldirection (FIG. 1). In the present example, the blades 20 of the twoinserts 10 and the blades 70 of the rear insert 60 do not overlap oneanother and positioned within a thin space in the vertical direction.

As follows, detailed configurations of the insert 10 will be described.The configurations of the rear insert 60 may be substantially the sameas the configurations of the fore insert 10. Therefore, followingdetailed description of the fore insert 10 may be applied to the rearinsert 60.

The insert 10 is substantially in a comb shape and integrally formed ofa resin material such as ABS resin by, for example, injection molding orstamping. The insert 10 includes the blades 20 and the base 12. The base12 is substantially in a bar shape. The blades 20 are extended from thebase 12 in the same direction perpendicularly to a longitudinaldirection of the base 12. The blades 20 are arranged in parallel alongthe width direction.

As shown in FIG. 5, each blade 20 and the base 12 are integrally formedto form a cantilever structure. The blade 20 includes a root end 22, twoarms 30, and a tip end 28, which are arranged in this order from thebase 12. The root end 22 extends from the base 12. The arms 30 areextended from the base 12. The tip end 28 is extended from the arms 30to form a free end of the cantilever structure. The tip end 28 ischamfered at its free end.

The two arms 30 are arranged in parallel. The two arms 30 form anaperture 30 a therebetween. The aperture 30 a is a single hollow spaceincluding a first slit 32 a, a center hole 35 a, and a second slit 38 ain this order. The dimension of the first slit 32 a, the center hole 35a, and the second slit 38 a are determined in consideration of aresilience of the two arms 30, a mechanical strength of the two arms 30,and an allowable communication (crosstalk) of air between the upperpassage 420 and the lower passage 440 (FIG. 2) through the aperture 30a.

The arms 30 are symmetrical with respect to an axis 20 a of the blade20. Each arm 30 includes a first linear portion 32, a first bent portion34, a center portion 35, a second bent portion 36, and a second linearportion 38, which are arranged in this order. The first bent portion 34,the center portion 35, and the second bent portion 36 form a C-shapedportion 25 projected outward from the axis 20 a in the width directionrelative to the first linear portion 32 and the second linear portion38.

The first linear portion 32 is extended linearly from the root end 22along the axis 20 a. The first bent portion 34 is extended from thefirst linear portion 32 and inclined outward from the axis 20 a. Thefirst bent portion 34 is inclined relative to the first linear portion32 and the center portion 35. The center portion 35 is extended linearlyalong the axis 20 a and is located outward relative to the first linearportion 32 and the second linear portion 38. The center portion 35 isconnected with the first linear portion 32 via the first bent portion34. The center portion 35 is further connected with the second linearportion 38 via the second bent portion 36. The second bent portion 36 isextended from the center portion 35 and is inclined inward toward theaxis 20 a. The second bent portion 36 is inclined relative to the centerportion 35 and the second linear portion 38. The second linear portion38 extends linearly from the second bent portion 36 to the tip end 28.The root end 22, the first linear portion 32, the center portion 35, thesecond linear portion 38, and the tip end 28 are extended substantiallyin parallel.

The two arms 30 form the first slit 32 a, the center hole 35 a, and thesecond slit 38 a therebetween. Specifically, the first linear portions32 form the first slit 32 a therebetween. The first bent portions 34,the center portions 35, and the second bent portions 36 form the centerhole 35 a thereamong. The second linear portions 38 form the second slit38 a therebetween. The first slit 32 a, the center hole 35 a, and thesecond slit 38 a are arranged in this order.

Each arm 30 is resiliently deformable (bendable) at its variousconnections. Specifically, each arm 30 is resiliently bendable at aconnection between the root end 22 and the first linear portion, at aconnection between the first linear portion and the first bent portion34, and at a connection between the first bent portion 34 and the centerportion 35. Each arm 30 is resiliently bendable further at a connectionbetween the center portion 35 and the second bent portion 36, at aconnection between the second bent portion 36 and the second linearportion, and at a connection between the second linear portion and thetip end 28.

The arms 30 and the connections among the arms 30, the root end 22, andthe tip end 28 form a spring portion 24. The spring portion 24 isconfigured to be resiliently squished (squishable) inward toward theaxis 20 a when being applied with an external force in the widthdirection. Specifically, the first linear portions 32 can be bentresiliently inward around the connections with the root end 22 to squishthe first slit 32 a. The first bent portions 34 can be bent resilientlyinward around the connections with the first linear portions and aroundthe connections with the center portions 35. The second bent portions 36can be bent resiliently inward around the connections with the secondlinear portions 38 and around the connections with the center portions35. Thus, the first bent portions 34 and the second bent portions 36squish the aperture 30 a with the center portions 35. The second linearportions 38 can be bent resiliently inward around the connections withthe tip end 28 to squish the second slit 38 a. In this way, the springportion 24 is resiliently deformable inward toward the axis 20 a.

As follows, a process to inert the blade 20 into the tubes 600 will bedescribed. As shown in FIG. 6, the blade 20 is to be inserted among fourtubes 600 including a first front tube 610, a second front tube 620, afirst rear tube 630, and a second rear tube 640. The first front tube610 and the second front tube 620 are located in parallel with eachother in a fore row. The first rear tube 630 and the second rear tube640 are located in parallel with each other in a rear row. The firstrear tube 630 is located linearly behind the first front tube 610. Thesecond rear tube 640 is located linearly behind the second front tube620. The first front tube 610, the second front tube 620, the first reartube 630, and the second rear tube 640 form an in-between clearance532A,

In the state of FIG. 6, the spring portion 24 has a width W in the widthdirection. The first front tube 610 and the second front tube 620 formthe clearance 532 having a width C in the width direction. The width Wis grater than the width C before the spring portion 24 is insertedbetween the first front tube 610 and the second front tube 620. In FIG.6, the tip end 28 is inserted between the first front tube 610 and thesecond front tube 620 frictionally or loosely. As the blade 20 isfurther inserted, the spring portion 24 makes contact with the firstfront tube 610 and the second front tube 620.

FIG. 7 shows a state in which the spring portion 24 is further insertedin the depth direction into the clearance 532 between the first fronttube 610 and the second front tube 620. In FIG. 7, the tip end 28 ispositioned in the in-between clearance 532 a. In addition, the springportion 24 is squished inward in the width direction and positionedbetween the first front tube 610 and the second front tube 620. The arms30 are interposed between the first front tube 610 and the second fronttube 620 and are resiliently bent inward in the width direction. Theaperture 30 a is squished inward in the width direction to enable thespring portion 24 to be positioned between the first front tube 610 andthe second front tube 620. In the state of FIG. 7, the width W of thespring portion 24 is reduced to be substantially equal to the width C ofthe clearance 532.

FIG. 8 shows a state in which the spring portion 24 is further insertedin the depth direction through the clearance 532 between the first fronttube 610 and the second front tube 620 into the clearance 532 betweenthe first rear tube 630 and the second rear tube 640. In FIG. 8, the tipend 28 is inserted into the clearance 532 between the first rear tube630 and the second rear tube 640. In addition, the spring portion 24 ispositioned in the in-between clearance 532 a. The root end 22 ispositioned in the clearance 532 between the first front tube 610 and thesecond front tube 620. In the state of FIG. 8, the spring portion 24 isbent back into its original form before being squished. Therefore, thewidth W of the spring portion 24 is restored to be grater than the widthC of the clearance 532 after the spring portion 24 is inserted into thein-between clearance 532A. Thus, the spring portion 24 maintains theposition of the blade 20 in the depth direction and restricts the blade20 from being pulled out of the evaporator 500. The inert 10 may beresiliently detachable from the evaporator 500 when, for example, theevaporator 500 is under a maintenance work.

In the state of FIG. 8, the spring portion 24 may be supportedfrictionally or loosely among the first front tube 610, the second fronttube 620, the first rear tube 630, and the second rear tube 640. Forexample, the spring portion 24 may be resiliently in contact with allthe first front tube 610, the second front tube 620, the first rear tube630, and the second rear tube 640 in four directions. In this case, asshown by the four arrows, the spring portion 24 may be applied withresilient forces F from the contacts with the first front tube 610, thesecond front tube 620, the first rear tube 630, and the second rear tube640. Alternatively, the spring portion 24 may be loosely supported byall or part of the first front tube 610, the second front tube 620, thefirst rear tube 630, and the second rear tube 640.

In addition, the tip end 28 may be supported frictionally or looselybetween the first rear tube 630 and the second rear tube 640. The rootend 22 may be supported frictionally or loosely between the first fronttube 610 and the second front tube 620.

The base 12 may be in contact with the first front tube 610 and thesecond front tube 620 in the depth direction. The tip end 28 of the foreinsert 10 may be in contact with the base 62 of the rear insert 60 (FIG.4), which is inserted from the opposed side in the depth direction.

The blades 20 may be placed on upper end surfaces the fins 700 of thesecond section 540 and supported by the fins 700 when positioned in thestate of FIG. 2.

(Modification of First Embodiment)

FIG. 9A is a sectional view taken along the line IXA-IXA in FIG. 5 andshowing a cross section of the center portions 35 and the center hole 35a. In the first embodiment, the dimension of the aperture 30 a isdetermined in consideration of, for example, the allowable communication(crosstalk) through the aperture 30 a.

FIG. 9B shows the spring portion 24 equipped with a film 210 accordingto a first modification. The film 210 is formed in the center hole 35 a.In addition to the center hole 35 a, the film 210 is also formedintegrally in the first slit 32 a and the second slit 38 a (FIG. 5) toscreen and/or block the first slit 32 a, the center hole 35 a, and thesecond slit 38 a entirely. The film 210 is formed of an elastic materialsuch as an ethylene propylene diene monomer rubber (EPDM rubber). Thefilm 210 may be formed by insert molding or by dipping the springportion 24 into a fluidic material of the film 210. In the example ofFIG. 9B, the film 210 is formed to bridge the center portions 35therebetween along the width direction. Specifically, the film 210 isformed between center positions of the center portions 35 in thethickness direction. The film 210 may be formed elastic enough to besquished and/or folded, when the spring portion 24 is squished andinserted between the tubes 600 (FIG. 7). The configuration of FIG. 9Bmay effectively restrict the crosstalk through the aperture 30 a.

FIG. 9C shows the spring portion 24 equipped with a film 220 accordingto a second modification. In addition to the center hole 35 a, the film220 is formed integrally in the first slit 32 a and the second slit 38 a(FIG. 5). The film 220 is formed of an elastic material such as an EPDMrubber. In the example of FIG. 9C, the film 220 is formed between alower edge of the center portion 35 on the left side in FIG. 9C and anupper edge of the center portion 35 on the right side in FIG. 9C. Thatis, the film 220 is inclined relative to both the width direction andthe thickness direction. The configuration of FIG. 9C may furtherfacilitate the film 220 to be folded and/or squished when the springportion 24 is squished and inserted between the tubes 600. Theconfiguration of FIG. 9C may also effectively restrict the crosstalkthrough the aperture 30 a.

FIG. 9D shows the spring portion 24 equipped with a film 240 accordingto a third modification. In addition to the center hole 35 a, the film240 is formed integrally in the first slit 32 a and the second slit 38 a(FIG. 5). The film 240 is formed of an elastic material such as an EPDMrubber. In the example of FIG. 9D, the film 240 includes a center film241 and a peripheral film 242. The center film 241 is convex and issubstantially in a dome shape. The center film 241 is projected upwardin FIG. 9D to form a dimple on the lower side in FIG. 9D. The centerfilm 241 is surrounded by the peripheral film 242. The peripheral film242 is formed between a lower edge of the center portion 35 on the leftside in FIG. 9D and a lower edge of the center portion 35 on the rightside in FIG. 9D. The film 240 is substantially in a planar shape andextends along the width direction. The configuration of FIG. 9D mayfurther facilitate the film 240 to be folded and/or squished at theupper end of the center film 241 in FIG. 9D and at the boundary betweenthe center film 241 and the peripheral film 242, when the spring portion24 is squished and inserted between the tubes 600. The configuration ofFIG. 9D may also effectively restrict the crosstalk through the aperture30 a.

Second Embodiment

As shown in FIG. 10, a second embodiment of the present disclosureemploys a first tube 1610 and a second tube 1620, which are arranged ina single row. Dissimilarly to the first embodiment, each of tubes 1610and 1620 is not separated in the direction of airflow and is integratedalong the airflow. In the state of FIG. 10, the fore insert 10 isinserted between the adjacent tubes 1610 and 1620, and the springportion 24 is squashed inward. Thus, the insert is resiliently andfrictionally supported by the adjacent two tubes 1610 and 1620. In theconfiguration of FIG. 10, the aperture 30 a is maintained as beingsquished. Thus, the configuration of the second embodiment may reducecrosstalk between through the aperture 30 a.

Third Embodiment

FIGS. 11 to 13 show a fore insert 110 according to the third embodiment.FIG. 11 is a top view when viewed along the arrow XI in FIG. 13. FIG. 12is a rear view when viewed along the arrow XII in FIG. 13. FIG. 13 is asectional view taken along the arrow XIII-XIII in FIG. 12. The insert110 may be employable in the evaporator 500 as described in the firstembodiment. In FIGS. 11 to 13, illustration of components of theevaporator, such as the tubes 600, the reinforcement 680, and the fins700, are omitted.

FIG. 11 shows a state where the fore insert 110 is inserted from the oneside in the depth direction, and a rear insert 160 is inserted from theother side in the depth direction. In FIG. 11, only the tip end 178 ofthe rear insert 160 is shown and remainder of the rear insert 160 isomitted. In FIG. 12, only a base 162 of the rear insert 160 is shown andremainder of the rear insert 160 is omitted.

Similarly to the first embodiment, the fore insert 110 and the rearinsert 160 are each comb-shaped. The fore insert 110 and the rear insert160 are opposed to each other in the depth direction. Blades 120 of thefore insert 110 and blades 170 of the rear insert 160 are arrangedalternately and located substantially at the same level in the verticaldirection. The configurations of the rear insert 160 may besubstantially the same as the configurations of the fore insert 110.

In FIG. 11, the insert 110 includes the blades 120 and a base 112. Theblades 120 are extended from the base 112 and are arranged in parallelalong the width direction. The blade 120 includes a root end 122, twoarms 130, and a tip end 128. The two arms 130 are arranged in parallelto form an aperture 130 a therebetween. The aperture 130 a is a singlehollow space including a first slit 132 a, a center hole 135 a, and asecond slit 138 a. The arms 130 and the connections among the arms 130,the root end 122, and the tip end 128 form a spring portion 124. Thespring portion 124 is configured to be resiliently squished (squishable)inward toward an axis 120 a when being applied with an external force inthe width direction.

The insert 110 employs the film 240 described above with reference toFIG. 9D. Specifically, the film 240 includes the center film 241 and theperipheral film 242. The center film 241 is substantially in an ovalshape and located substantially at a center of the film 240 in both thewidth and length directions. The peripheral film 242 entirely screensthe aperture 130 a to close the first slit 132 a, the center hole 135 a,and the second slit 138 a entirely.

The insert 110 has an elastic base 244 formed on the base 112. Theelastic base 244 is formed of a same material, such as EPDM rubber, asthat of the film 240 and is integrally formed with the film 240.Specifically, the elastic base 244 bridges the film 240 of each of theblades 120 into a singular form. The elastic base 244 has an elastic end244 a opposed to a tip end 178 of the blade 170. The film 240 and theelastic base 244 may be insert-molded on the insert 110. Alternatively,the film 240 and the elastic base 244 may be formed separately from theinsert 110 and may be adhered onto the insert 110.

As shown in FIG. 13, the base 112 has a rigid end 112 a, and the elasticbase 244 has the elastic end 244 a. The elastic end 244 a is projectedin the length direction leftward in FIG. 13 relative to the rigid end112 a. That is, the elastic end 244 a is raised stepwise relative to therigid end 112 a. Therefore, when the insert 110 is inserted into theevaporator 500, the elastic end 244 a first makes contact with lateralsurfaces of the tubes 600 and the fins 700. When the insert 110 isfurther inserted into the evaporator 500, the elastic end 244 a mayelastically deform to fill a gap between the elastic end 244 a and thelateral surfaces of the tubes 600 and the fins 700. In addition, theelastic deformation of the elastic end 244 a may facilitate alignment ofthe insert 110 relative to the evaporator 500. The elastic end 244 a maybe configured elastically to receive the tip end 128 of the blade 120and to reduce a gap between the tip end 128 and the base 162.

The base 112 has two protrusions 142 between the blades 120, which areadjacent to each other. The two protrusions 142 are projected from thebase 112 in the length direction. The two protrusions 142 are configuredto receive the tip end 178 of the blade 170 and to fill a gap betweenthe tip end 178, the base 112, and the tube 600 (FIG. 8). The root end122 (FIG. 11) forms a recess 144 dented in the thickness direction (FIG.13).

Fourth Embodiment

FIGS. 14 to 15B show blades 320 of a fore insert 310 according to thefourth embodiment. FIG. 15A is a perspective sectional view taken alongthe arrow XVA-XVA in FIG. 14. The insert 310 may be employable in theevaporator 500 as described in the first embodiment.

Similarly to the first embodiment, the fore insert 310 and a rear insert360 are each comb-shaped. The fore insert 310 and the rear insert 360are opposed to each other in the depth direction, such that the blades320 of the fore insert 310 and blades 370 of the rear insert 360 arearranged alternately. The configurations of the rear insert 360 may besubstantially the same as the configurations of the fore insert 310. Theinsert 310 includes the blades 320 and a base 312. The blades 320 areextended from the base 312 and are arranged in parallel along the widthdirection. Similarly to the third embodiment, the base 312 has twoprotrusions 342 between the blades 320, which are adjacent to eachother. The two protrusions 342 are projected from the base 312 in thelength direction.

The blade 320 includes a root end 322, two arms 330, and a tip end 328.The arm 330 includes a first linear portion 332, a center portion 335,and a second linear portion 338, which are arranged in this order. Thearm 330 has a first recess 332 a, a center recess 335 a, and a secondrecess 338 a. The arm 330 further has a thick portion 343 and a thinportion 344.

As shown in FIG. 15A, cross sections of the arms 330 are point-symmetricabout an axis 320 a of the blade 320. The axis 320 a passes along theaxial direction through the center point of the cross section of theblade 320. One of the arms 330 on the left side in FIG. 15A has thefirst recess 332 a and the center recess 335 a, which are denteddownward in FIG. 15A, and the second recess 338 a (not illustrated inFIG. 15A) is also dented downward similarly. The other of the arms 330on the right side in FIG. 15A has the first recess 332 a and the centerrecess 335 a, which are dented upward in FIG. 15A, and the second recess338 a (not illustrated in FIG. 15A) is also dented upward similarly.

The thin portion 344 is substantially in a thin plate shape and definesa bottom surface of the first recess 332 a, the center recess 335 a, andthe second recess 338 a. The thick portion 343 is a remainder of the arm330 excluding the thin portion 344.

The blade 320 may be formed of resin by injection molding. Specifically,molding dies (not shown) are mated from the upper side and the lowerside in FIG. 15A to form a molding cavity, and resin is injected intothe molding cavity to mold the blade 320. When molding, the upper andlower dies may form a small gap to form a flash 345 to bridge edges ofthe thin portions 344 therebetween. The flash 345 extends along theboundary between the thin portions 344 in the direction of the axis 320a.

In FIG. 14A, the arms 330 are resiliently deformable (bendable) at, forexample, pivots 331 and 339. The arms 330 and the pivots 331 and 339 mayform a spring portion 324. The spring portion 324 is configured to beresiliently squished (squishable) inward toward the axis 320 a whenbeing applied with an external force in the width direction.

As shown in FIG. 15B, when an external force is applied to the centerportion 335 in the width direction along the arrows, the flash 345 iscrushed to enable the thin portions 344 to move inward in the widthdirection around the pivot 331. The thin portions 344 are movable withinthe clearance formed by the recesses 332 a, 335 a, 338 a, whileoverlapping one another in the thickness direction. When the externalforce is released, the thin portions 344 resiliently recover in shape tobe in the state of FIG. 15A. Thus, the spring portion 324 according tothe present embodiment enables the blades 320 to be inserted between thetubes 600 of the evaporator 500, similarly to the first embodiment, asdescribed above with reference to FIGS. 6 to 8.

In FIG. 14, the center portion 335 may have a thin notch 335 b to extendthrough the thin portion 344 in the thickness direction. In the presentconfiguration, when an external force is applied to the center portion335 in the width direction, the thin portion 344 is sheared at the thinnotch 335 b to form a crevasse (crack) inside the center portion 335.With the thin notch 335 b, the thin portion 344 less impedes the centerportion 335 from bending, by sharing itself, thereby to facilitate theresilient deformation of the center portion 335. The thin notch 335 bmay be formed by an additional thin blade portion to the molding dies.The thin notch 335 b may be in a narrow slit, a V-shaped slit, and/or aU-shaped slit. The thin notch 335 b may be a thin flash, which can beeasily crushed and sheared when the center portion 335 is bent.

The flash 345 may not be formed. In this case, the thin portions 344 mayform a thin slit therebetween along the axis 320 a.

The insert 320 according to the fourth embodiment may reduce leakage ofairflow therethrough, without an additional film to screen an aperture.

The insert 320 of the fourth embodiment may be additionally formed withthe elastic base 244 of the third embodiment. The insert 320 of thefourth embodiment may be additionally formed with the recess 144 of thethird embodiment.

Fifth Embodiment

FIG. 16 shows an HVAC system according to the fifth embodiment. Thepresent embodiment employs a singular fan 730 to cause airflows in boththe upper passage 420 and the lower passage 440. The present embodimentemploys a valve 740 equipped between the fan 730 and the partition 430and located on the upstream side of the evaporator 500. The valve 740is, for example, a butterfly valve including a planar body 742 and arotational shaft 744 to form a cantilever structure. The body 742 isrotatable around the rotational shaft 744 to control distribution ofairflow between the upper passage 420 and the lower passage 440. In theexample of FIG. 16, the valve 740 is directed upward in FIG. 16 to causeairflow in the lower passage 440 greater than airflow in the upperpassage 420. The above-described evaporator 500 having the insert may bealso effectively applicable also to the HVAC shown in FIG. 16.

Other Embodiment

The fins 700 and the tubes 600 may be, for example, stacked and brazedfirst to form the core of the evaporator 500. Subsequently, theclearance 532 may be formed by thrusting a blade-shaped core into thefins 700 thereby to pre-punch the fins 700 at a position correspondingto the intermediate section 530 to enable insertions of the insert.Alternatively or in addition, the blades of the insert may be insertedinto clearances, which are originally formed between the wave-shapedfins 700 and the tubes 600. Alternatively or in addition, each fin 700of the first section 520 may be arranged to extend downward from itsupper end to the intermediate section 530, and each fin 700 of thesecond section 540 may be arranged to extend from its lower end upwardto the intermediate section 530. In this way, the clearance 532 may beformed between the first section 520 and the second section 540, withoutpunching the fins 700.

The number of the blades 20 may be two or more to form the comb shape ofthe insert. The spring portion 24 may be formed in at least one of theblades. For example, the spring portion 24 may be formed in three bladesincluding one blade located at the center of the insert and two bladeslocated at both ends of the insert.

The fore insert 10 and the rear insert 60 may be integrated into asingle piece having all the blades 20 enough to partition the firstsection 520 from the second section 540. In this case, the insert may beinserted to the intermediate section 530 from only one direction. Theinsert may be formed of a metallic material, such as aluminum alloy, bycasting or stamping.

The fins 700 may be continual between the first section 520 and thesecond section 540. In this case, the blades 20 may be inserted into airpassages formed between the fins 700 and the tubes 600. In this case,the air passages, into which the blades 20 are inserted, may function asclearances 532.

The configurations of the present disclosure are not limited to beemployed in an evaporator 500 and may be employed in various heatexchangers such as a condenser and/or radiator. The configuration of thepresent disclosure may be employed in a heat exchanger for an exteriorand interior two-layer air conditioning system. In this case, the heatexchanger may be partitioned for separating exterior air passage and aninterior air passage.

For purposes of clarity, the same reference numbers will be used in thedrawings to identify similar elements. As used herein, the phrase atleast one of A, B, and C should be construed to mean a logical (A or Bor C), using a non-exclusive logical or.

It should be appreciated that while the processes of the embodiments ofthe present disclosure have been described herein as including aspecific sequence of steps, further alternative embodiments includingvarious other sequences of these steps and/or additional steps notdisclosed herein are intended to be within the steps of the presentdisclosure.

While the present disclosure has been described with reference topreferred embodiments thereof, it is to be understood that thedisclosure is not limited to the preferred embodiments andconstructions. The present disclosure is intended to cover variousmodification and equivalent arrangements. In addition, while the variouscombinations and configurations, which are preferred, other combinationsand configurations, including more, less or only a single element, arealso within the spirit and scope of the present disclosure.

What is claimed is:
 1. An insert for a heat exchanger having a pluralityof tubes, the insert comprising: a base; and a plurality of bladesextending from the base, wherein at least one of the blades has a springportion, which is resiliently deformable and configured to beresiliently inserted between two of the tubes, the spring portionincludes two arms, one of the two arms has one thin portion defining onerecess dented in one direction in a thickness direction, an other of thetwo arms has an other thin portion defining an other recess dented in another direction in the thickness direction, and the one thin portion andthe other thin portion are resiliently movable in a width directionwithin a clearance formed by the recesses, while overlapping one anotherin the thickness direction, wherein the one thin portion and the otherthin portion have a flash therebetween, before the one thin portion andthe other thin portion are resiliently moved in the width direction, andthe one thin portion and the other thin portion are configured tooverlap one another in the thickness direction, when resiliently movedin the width direction, while crushing the flash.
 2. The insertaccording to claim 1, wherein the base and the blades are integrallyformed in a comb shape, and the blades are extended from the baseperpendicularly to the base.
 3. The insert according to claim 1, whereinthe spring portion includes two arms forming an aperture therebetween.4. The insert according to claim 3, wherein the two arms includeC-shaped portions, respectively, and the C-shaped portions are projectedoutward.
 5. The insert according to claim 4, wherein the two arms aresymmetrical with respect to an axis of the at least one of the blades.6. The insert according to claim 4, wherein the at least one of theblades further includes a tip end and a root end, the root end extendsfrom the base, the C-shaped portions extends from the root end, and thetip end extends from the spring portion.
 7. The insert according toclaim 6, wherein the C-shaped portions are projected outward relative tothe root end and the tip end.
 8. The insert according to claim 7,wherein the aperture further includes a first slit, the arms furtherincludes first linear portions, respectively, the first linear portionsare located between the root end and the C-shaped portions, and thefirst linear portions form the first slit therebetween.
 9. The insertaccording to claim 8, wherein the aperture further includes a secondslit, the arms further includes second linear portions, respectively,the second linear portions are located between the C-shaped portions andthe tip end, and the second linear portions form the second slittherebetween.
 10. The insert according to claim 9, wherein the aperturefurther includes a center hole, the C-shaped portions form the centerhole therebetween, and the first slit, the center hole, and the secondslit are arranged in this order to form a single hollow space.
 11. Theinsert according to claim 10, wherein the C-shaped portions eachincludes a first bent portion, a center portion, and a second bentportion, which are connected in this order, and the center portion islocated outside the first linear portion and the second linear portion.12. The insert according to claim 1, wherein the spring portion has awidth greater than a width of a clearance between two of the tubes. 13.The insert according to claim 1, wherein the spring portion isconfigured to be inserted in the tubes including a first front tube, asecond front tube, a first rear tube, and a second rear tube, and thespring portion is configured to be resiliently in contact with all thefirst front tube, the second front tube, the first rear tube, and thesecond rear tube in four directions.
 14. The insert according to claim1, wherein the base has an elastic base configured to be elastically incontact with the tubes.
 15. The insert according to claim 1, wherein thebase has a plurality of protrusions projected from the base and locatedbetween two of the blades, which are adjacent to each other.